Turbine generator regenerative braking system

ABSTRACT

A turbine generator regenerative braking system is for an automotive or other vehicle having ground engaging wheels and an electrical energy storage device. The braking system comprises an hydraulic fluid turbine generator having an electrical power output connected to the electrical energy storage device, a plurality of hydraulic fluid pumps, an actuation system for operatively connecting/starting pumping action, and a hydraulic fluid circuit connecting the hydraulic pumps to the turbine generator. In some versions of the system, a hydraulic pump, a clutch and an adjustable flow nozzle will be dedicated to each ground engaging wheel of the vehicle. In operation, braking is preferably initiated by the actuation of a brake master cylinder which provides hydraulic pressure to cause each rotating wheel with its corresponding hydraulic pump to engage. The pressurized fluid output of each pump is then fed to the turbine through the adjustable-flow nozzle causing the flywheel, and thus the generator, to rotate. The rotation of the turbine generator produces electrical power which is transmitted to the vehicle&#39;s electrical energy storage device.

This application is a continuation of, and claims priority from, U.S.patent application Ser. No. 10/119,531, filed Apr. 8, 2002, entitled“Turbine Generator Regenerative Braking System”, issuing as U.S. Pat.No. 6,758,295 on Jul. 6, 2004, the disclosure of which is incorporatedherein by this reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates, in general, to braking systems and, moreparticularly, to regenerative braking systems for vehicles. Thisinvention relates to a regenerative braking system that slows a vehicleby operatively connecting a hydraulic pump system to the vehicle'srotating wheels to pump fluid to a turbine for electric generation.

2. Related Art

The prior art is replete with approaches to extracting, storing andbeneficially using the energy usually dissipated during vehicle braking.These approaches in part include many combinations and interconnectionsof flywheels, hydraulic and pneumatic accumulators, motors, pumps, andthe like. None of the known prior art, however, incorporates a turbinegenerator for regenerative braking and electrical energy generation, asin the present invention. The following brief review of some of theprior art will be useful in establishing the novelty and utility of thepresent invention.

Bultmann (U.S. Pat. No. 4,114,734) has disclosed a braking system havinga hydrodynamic coupling driven by the vehicle, wherein the operatingfluid is conducted into an external circulatory system by way of acooler or radiator. This hydrodynamic coupling also serves as a feedpump for the operating fluid and is operatively connected with a turbineto drive a separate cooling fan. In this manner, heat removal from thebraking system may be facilitated.

Smitley (U.S. Pat. No. 4,342,371) also teaches a flywheel approach tostoring and supplying energy for vehicles. The flywheel is selectivelyconnected to the power train of a vehicle and absorbs energy from thevehicle's ground engaging wheels during the deceleration of the vehicle.This process provides at least a degree of vehicular braking. A clutchis also provided to selectively engage/disengage the flywheel connectionto the wheels.

Chang (U.S. Pat. No. 4,798,053) employs a vehicle's engine to compressair when the vehicle decelerates and reuses the air thus-compressed todrive an air motor which assists in moving the vehicle when it isunderway again.

Gray et al. (U.S. Pat. No. 5,505.527) provides a vehicular powertrainwith regenerative braking having a pump/motor combination connected tothe vehicle's drive wheels. In the vehicle's braking mode, the pumpcomes into play and charges an accumulator. When it is desired toaccelerate the vehicle, the accumulator releases its stored energy byproviding hydraulic power to the motor which, in turn, drives thevehicle's wheels. Controls and switches are provided to implement andcoordinate the various functions of the components.

Ellis et al. (U.S. Pat. No. 5,931,249) disclose a kinetic energy storagesystem that uses a flywheel with a motor generator to store energy. Theflywheel rotates at a high speed in a vacuum. The flywheel may also beused to power the vehicle.

Martin-Gerez (U.S. Pat. No. 6,068,351) teaches an axle-driven pumpingmechanism used to pressurize a volume of hydraulic fluid in response toa braking command. The fluid thus-pressurized activates a turbine thatis used to drive a cooling fan directed at a radiator used to dissipateheat in the hydraulic fluid.

As can readily seen from the above review, the prior art is silent withrespect to extracting energy to affect vehicular braking byhydraulically turning a turbine generator with a fluid-jet powered bythe rotation of the wheels. No prior art approach is known to anticipatethe present invention's innovative incorporation of a turbine generatoractuated by fluid-jet energy recovered during the braking phase of avehicle's operation. The extraction of energy by the fluid-jet-poweredturbine generator aids in braking the vehicle and the electrical energythe turbine generates is stored in the vehicle's electrical storagesystem, typically batteries. However, other electrical storage systemsmay also be used like, for example, ultra-capacitors (see“electriccomponents.com”).

Thus it is a primary objective of this invention to provide a brakingsystem that generates electrical energy while facilitating braking ofthe vehicle. It is another object of this invention to include a turbinegenerator in such a system that is powered by a fluid-jet driven by thevehicle's wheels. It is a further object of this invention to store thegenerated electrical energy for the later use by the vehicle. It is yetanother object of this invention to provide such a system that is robustand inexpensive to manufacture, install and operate. Another object ofthis invention is to provide a turbine generator regenerative brakingsystem that is applicable to any apparatus requiring braking independentof the primary motive power.

SUMMARY OF THE INVENTION

This invention is a turbine generator regenerative braking system for avehicle having ground-engaging wheels and an electrical energy storagedevice. The braking system comprises an hydraulic fluid turbinegenerator having an electrical power output connected to the electricalenergy storage device, one or more hydraulic fluid pumps, and anhydraulic fluid circuit operatively and cooperatively connecting thehydraulic pump(s) to the turbine generator. Further, the braking systemcomprises an actuator system adapted to operatively connect the fluidpump(s) to the wheel(s) and to actuate the pump operation, powered bythe wheel(s), for pumping fluid through the hydraulic fluid circuit. Anoperator's foot pedal or other operator control means is adapted tosignal the actuator system, preferably controlling application of thebrakes in an incremental manner. Preferably, the hydraulic fluid circuitcomprises outlet nozzles through which the hydraulic fluid is forced tojet against cups/blades of the turbine, for generation of electricity.

By slowing the vehicle, via a method that comprises operative connectionof the wheels to fluid pumps that power a turbine, the invented systemtransfers some of the vehicle kinetic energy into electrical energyrather than dissipating the energy as heat during conventionalfrictional slowing by brake shoes. The system preferably has adjustmentfeatures for controlling/varying the amount of braking, so that thebraking system may be used during travel for slowing or for slowing andstopping. Adjustment features preferably comprise the jet nozzles beingadjustable to vary flow restriction in the hydraulic line(s). Further,another adjustment feature may comprise a variable pump rate such aswith a variable positive-displacement pump. The preferred fluid turbinegenerator comprises a flywheel, a plurality of cup blades on theflywheel like a Pelton wheel, and an electrical generator section. Theflywheel may have fan-like blades or other structure on which the fluidjets impinge. Optionally, power-take-off (PTO) may be providedmechanically from the flywheel shaft.

In most embodiments of this invention, each wheel may power, and, hence,may be slowed by, the fluid-jet-turbine system. Each wheel may beoperatively connected/connectable to its own respective fluid hydraulicpump and its own respective fluid line and nozzle, so that a pump andnozzle system is connected to and dedicated to each of the plurality ofwheels.

The actuation system comprises a mechanism for starting and stoppingpump operation in response to whether and how much the operator isapplying the brakes. The actuation system comprises operative connectionof the rotating wheel(s) to the pump(s), which may be accomplished invarious ways comprising mechanical connection/coupling of a pump thatautomatically pumps when connected, start-up of the pump separate frommechanical connection, or start-up or speeding-up of a pump that isalready connected to the wheel. For example, the pump device may bemechanically engaged with the wheel at all times, but with the pumpadapted to not pump fluid until braking is actuated by the operator.Such a system, for example, could comprise avariable-positive-displacement pump that is adapted to be at a zeropumping rate during normal non-braking operation but that increase to anon-zero pumping rate when the brake is actuated. In such a case,actuation of the pump would not necessarily affect physical connectionof the pump to the wheel by a clutch, but actuation would comprisestartup of the already-connected pump and/or increasing of the pumpingrate to the desired level. Alternatively, the pump may be disengagedmechanically from the wheel until braking is actuated, at which time aclutch or other coupling mechanism mechanically connects the pump to thewheel and actuates pumping of fluid.

The actuation system may comprise various types of actuation, forexample, mechanical, hydraulic, air, electrical switching, or othermechanism for causing/allowing the engagement/coupling of the pump tothe wheel and/or starting up or increasing the speed or displacementvolume of the pump. The actuation is controlled by the operator of thevehicle, and preferred mechanism is a hydraulic master cylinder poweredby the driver pressing on a foot pedal in the vehicle cab, and conduitsconveying hydraulic fluid to (and hence operating) the preferred clutchsystem, pump start-up system, or variable rate/displacement mechanismadjustment system. After actuation, the pump is fed by a hydraulicreservoir and powered by the vehicle wheel(s) to force fluid flowthrough the hydraulic line downstream of each pump to its correspondingadjustable-flow nozzle for delivering/spraying hydraulic fluid againstthe turbine's blades/cups. The fluid flow from each nozzle impinges onthe preferred cup blades, causing the turbine flywheel to rotate, andthus the generator, to rotate. The rotation of the turbine generatorthus generates electrical power which is transmitted to the vehicle'selectrical energy storage device.

In effect, therefore, this extraction of power from the wheels, to pumpfluid through the conduits and through the nozzles, initiates thebraking action on each of the wheels. Further braking action may beachieved by a closing movement of needle valves within the nozzles,which provides an increased restriction to fluid flow. This closingmovement is preferably controlled by the operator's action in thevehicle cab, that is, preferably pushing harder on the brake pedal. Thefluid dynamics affected by closing of the nozzles may include increasedpressure/head in the output circuit of each pump, reduced fluid flowrate, reduced pump speed, via this additional work load on the pump and,therefore, on the wheel(s).

The nozzle(s) may be adapted to be completely or substantiallycompletely closed, wherein the hydraulic system will “lock up,” so thatfluid flow and pumping stops, and, hence, wheel rotation also stops.Such a “lock up” system may adapt the invented braking system tosynergistically serve as a parking brake system for the vehicle.

After reviewing this Description and Drawings, one of skill in the artwill understand that an actuation system may be designed to operativelycouple a rotating wheel/axle of the vehicle to a pump by a clutchsystem, or to start-up/speed-up a pump already mechanically connected tothe wheel/axle of the vehicle, depending on the type of pump chosen.Various types of liquid pumps adapted or adaptable to be powered byrotational movement are known and may be installed in embodiments of theinvention.

Heat may need to be removed from the pump circuit, for example, due toenergy being dissipated at the site of the restricted nozzle(s) duringnozzle(s) operation. Conventional heat transfer, including cooling finsor fan-assisted heat exchange with air, may be provided.

The turbine generator continues to rotate and generate electrical powerafter the flow of hydraulic fluid is removed from the cup blades of theturbine. In this fashion, nearly all of the kinetic energy stored in therotating components of the turbine generator is recovered for use by thevehicle.

This invention of a turbine generator regenerative braking system isapplicable to vehicles powered by internal combustion engines, pureelectrical vehicles and hybrid vehicles. In fact, the inventor believesthis invention has universal applicability to any device requiring ameans for braking which may be adapted for energy conservation off therotating shaft.

These and many other features and attendant advantages of the inventionwill become apparent, as the invention becomes better understood byreference to the following detailed descriptions and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of one embodiment of the invention asapplied to a four-wheeled vehicle.

FIG. 2 is a schematic elevation view of one embodiment of the inventionshowing key components of the turbine generator, pumps and nozzles.

FIG. 3 is a cutaway view of one embodiment of a turbine generator and anopen nozzle according to the invention.

FIG. 4 is a cutaway view of the turbine generator and nozzle embodimentof FIG. 3, wherein the nozzle is closed.

FIG. 5 is a schematic view of steps for one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIG. 1, this invention of a turbine generatorregenerative braking system 10 for an automotive vehicle having groundengaging wheels 18 and electrical energy storage device 15, compriseshydraulic fluid turbine generator 80 having an electrical power output180 connected to the electrical energy storage device 15, a plurality ofhydraulic fluid pumps 30 (one each at the wheels 18), an hydraulic fluidcircuit operatively and cooperatively connecting the hydraulic pumps tothe turbine generator, and an actuation system(s) 35 for causing thepump to be operative engaged with the wheel or to otherwise beginpumping at an appropriate flow-rate or flow-rates to slow the wheel. Asdiscussed in the Summary, the actuation system may comprise, forexample, a clutch assembly, a positive-displacement-variation system fora positive displacement pump, or other system operatively connectedbetween the wheels of the vehicle and the hydraulic fluid pump toengage/start-up/increase pumping when the driver/operator brakes thevehicle. In some embodiments, pumps 30 have a fixed displacement with aclutch, however, some embodiments incorporate variable displacementpumps without a clutch.

In FIG. 1, each actuation system 35 is shown as powered by a hydraulicline 24 from a hydraulic master cylinder 22 operated by the vehicle cabbrake foot pedal 122. The actuation may be an on-off system, forexample, wherein pressing on the pedal engages the clutch and harderpressing on the pedal then further applies the brakes by adjusting theneedle valves in the nozzles for increased braking (discussed below).Or, the actuation may be an adjustable system, for example, whereinpressing on the pedal “starts up” the pump at a nominal rate or volumeand further pressing on the pedal increases the rate or volume forincreased braking.

Referring now to FIGS. 1 and 2, the turbine generator further includesgenerator section 14, casing 81, turbine shaft 85, flywheel portion 84and runner portion 82. The runner has a plurality of cup blades 83.FIGS. 1 and 2 also show hydraulic fluid reservoir 89, which serves asthe feed reservoir for supplying the pumps 30 and receiving circulatedfluid exiting the turbine, interconnecting hydraulic lines 38 from thereservoir to the pumps, and lines 39 from the pumps to the adjustablenozzles 90, from which the fluid sprays/jets against the turbine. brakemaster cylinder 22, adjustable nozzles 90 and interconnecting hydraulicfluid conduits 24, 38, 39.

In FIGS. 1 and 2, there are shown arrangements of hydraulic lines 24containing hydraulic fluid from the master cylinder system that travelto and control the actuation system 35 and also the adjustable needlevalves in the nozzles 90. One may see that thismaster-cylinder-actuator-nozzle-hydraulic-fluid system is preferablyseparate from the pump-nozzle-turbine hydraulic system, and is a controlsystem for actuating and/or adjusting the clutch/pump system and foradjusting the variable valving for the nozzles. Thus, this controlsystem serves to control the start of braking, the force of braking, andthe duration of braking by controlling engagement of the pumps on thewheels and the workload applied to the pumps and the wheels.

FIGS. 3 and 4 show adjustable nozzles 90 have body 91, cylinder bore 92,valve opening spring 99, and needle valve 93. The needle valve haspiston end 95 and face end 96. FIG. 3 shows the needle valve in its openposition and FIG. 4 shows the valve in its closed position, andtherefore also suggests the variable positions and variable flowratesinbetween these two positions.

As shown in FIGS. 1 and 2, the braking system and vehicle of thisinvention may also include controller 16. This controller uses knownmethods and components to assure effective management of thepower/energy generated and used by the vehicle. Further, additionalcontroller(s) systems may be used to provide safeguards and controls forproper operation of the braking system. For example, the nozzledirection may be adjusted to impact the flywheel cups or blades at anoptimum angle, depending on flywheel shaft rpm. Also, drag by theturbine generator may be adjusted by adjusting the fields of itscooperating magnets, for example.

In operation, braking is initiated by the actuation of brake mastercylinder 22 which provides hydraulic pressure to each clutch/actuator 35and to each nozzle 90. In clutch embodiments, this causes each clutch toengage and mechanically connect each rotating wheel 18 with itscorresponding hydraulic pump 30. Actuation of the master cylinder alsocauses needle valves 93 to adjust their position, thus allowing thepressurized fluid output of each pump to impinge on cup blades 83 ofrunner 82 at appropriate rates/volumes, causing turbine flywheel 84 andgenerator section 14 to rotate. The rotation of the turbine generatorthus produces electrical power which is transmitted to the vehicle'selectrical energy storage device. This extraction of power from thehydraulic circuit initiates the braking action on each of the wheels.Further braking action is achieved by reducing the fluid flow in eachpump's output circuit by a closing movement of the needle valves withinthe nozzle bodies as controlled by the master cylinder. This actionincreases the pressure in the output circuit of each pump, whichincreases the energy required by the pump to accomplish a given amountof pumping, which translates to a reduction of the pump's speed andfurther slowing of the wheels, via the clutches or other linkage to thewheels.

It is a preferred and important feature of this invention that theturbine generator continues to rotate and generate electrical powerafter the flow of hydraulic fluid is removed from the cup blades of theturbine. In this fashion, nearly all of the kinetic energy stored in therotating components of the turbine generator is recovered for use by thevehicle.

Although this invention has been described above with reference toparticular means, materials and embodiments, it is to be understood thatthe invention is not limited to these disclosed particulars, but extendsinstead to all equivalents within the scope of the following claims.

1. A turbine generator regenerative braking system for braking arotating shaft, said braking system comprising: a rotating shaft of apiece of machinery; a plurality of hydraulic fluid pumps adapted to bemechanically linked to said rotating shaft so that said rotating shaftpowers the pumps; a hydraulic fluid circuit having one end in fluidcommunication with said hydraulic pumps and a second end comprising anadjustable-outlet jet nozzle; an hydraulic fluid turbine generatorpositioned near said jet nozzle and having an electrical power outputconnected to a battery device; wherein said rotating shaft is slowed bymechanically linking said rotating shaft to said hydraulic fluid pumpsto pump hydraulic fluid to the jet nozzle so that the jet nozzle sprayshydraulic fluid on the generator to generate electricity; wherein saidrotating shaft is stopped by closing said jet nozzle; and wherein saidjet nozzle is an adjustable direction needle valve.
 2. A turbinegenerator regenerative braking system according to claim 1 wherein saidrotating shaft is a combustion engine shaft.
 3. A turbine generatorregenerative braking system according to claim 1 wherein said rotatingshaft is a combustion engine vehicle shaft.
 4. A turbine generatorregenerative braking system according to claim 1 wherein said rotatingshaft is a combustion engine vehicle axle.
 5. A turbine generatorregenerative braking system according to claim 1 wherein said fluidturbine generator further includes flywheel, having a plurality of cups.6. A turbine generator regenerative braking system according to claim 1wherein said pumps have a positive displacement.
 7. A turbine generatorregenerative braking system according to claim 6 wherein said positivedisplacement pumps are of the fixed displacement type.
 8. A turbinegenerator regenerative braking system according to claim 6 wherein saidpositive displacement pumps are of a variable displacement type.
 9. Amethod of regeneratively braking a rotating shaft, the methodcomprising: providing a hydraulic fluid circuit comprising a hydraulicpump at one end and an adjustable-outlet jet nozzle at a second end;providing an hydraulic fluid turbine generator near said jet nozzle andconnecting an electrical power output of said turbine generator to abattery device; mechanically linking said hydraulic pump to a rotatingshaft of a piece of machinery so that said hydraulic fluid pump isactuated to pump hydraulic fluid to the jet nozzle to spray hydraulicfluid on the generator to generate electricity; and wherein saidrotating shaft is slowed by the work load of said pumping of thehydraulic fluid; and wherein said jet nozzle is an adjustable-directionneedle valve.
 10. A method according to claim 9, further comprisingclosing said jet nozzle to stop flow of said hydraulic fluid and stoprotation of said rotating shaft.
 11. A method according to claim 9,wherein said rotating shaft is a combustion engine shaft.
 12. A methodaccording to claim 9, wherein said rotating shaft is a combustion enginevehicle shaft.
 13. A method according to claim 9, wherein said rotatingshaft is a combustion engine vehicle axle.
 14. A method according toclaim 9, wherein said fluid turbine generator further includes flywheel,having a plurality of cups.
 15. A method according to claim 9 whereinsaid pump is a positive displacement pump of fixed displacement.
 16. Amethod according to claim 9 wherein said pump is a positive displacementpump of variable displacement.